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Fully engineered solutions.
Datasheet
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Energetic
Drives has designed a series of low ratio gearboxes that fit our low
speed permanent magnet generators. The torque transfer required in
these unique gearboxes is the motivating factor behind this patent
pending design.
Traditional
gearbox designs
utilize multiple stages (as many as 4 separate stages), large ratios
(up to 69:1 or more) and high speeds (1500-1800RPM).
Energetic
Drives design philosophy allows us to produce gearboxes for wind
turbines rated 250KW to 1.5MW maintaining consistency throughout the
range.
Advantages include but are not limited to the following:
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A 330 KW turbine gearbox has only one stage (3.866:1 ratio)
with a
low speed (145 RPM) input shaft. The result is less noise and simple
lubrication (see Figures 1 thru 4 above).
•
Turbines rated above 330 KW (500, 750, 1000, 1200, 1500 and 2000 KW)
have two stage gearboxes. The first stage is the same as the 330 KW and
allows us to accommodate 2, 3 or 4 permanent magnet motor/generators
(see Figure 5 below).
•
The second stage allows us to accommodate the desired cut-in and
cut-out blade speed which is dictated by the turbine
location, wind speed data and blade design. The input shaft
has
the same low speed transmission used in the 330 KW design (145 RPM).
•
The size of the second stage gears are reduced because of
minimal
tooth stresses.
•
The gearbox requires simple lubrication and the low speed design has no
requirement for a special chilling system used in the traditional wind
turbine gearbox designs.
•
The gearbox is inherently low maintenance due to the low RPM
and
an internal design that incorporates odd and even gearing resulting
in random tooth alignments.
•
Utilizing the 330 KW gearbox elements allows a reduced inventory of
components, simple maintenance and increased longevity of the gearbox.
Helical
gears are similar to spur gears except that the gear teeth are at an
angle with the axis of the gears. A helical gear is termed
right
handed or left handed as determined by the direction the teeth slope
away from the viewer looking at the top gear surface along the axis of
the gear. Meshing helical gears must be of opposite hand.
Meshed helical gears can be at an angle to each other (up to
90º). The helical gear provides a smoother mesh and can be
operated at greater speeds than a straight spur gear. In
operation, helical gears generate axial shaft forces in addition to the
radial shaft force generated by normal spur gears.
Explanation of the
Design Philosophy
(with references by Dr. Semion Stolyar)
In
operation the initial tooth contact of a helical gear is a point which
develops into a full line contact as the gear rotates. This is a
smoother cycle than a spur which has an initial line contact.
Spur gears are generally not run at peripheral speed of more than
10m/s. Helical gears can be run at speed exceeding 50m/s when
accurately machined and balanced.
The ASME
designed gearbox applies the standards of helical gears and spur gears
seen below:
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Click
on the picture below to read about noise problems that occur with
traditional turbines. Our low-speed, low-ratio gearboxes resolve
these issues.
 
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Energetic
Drives engineers custom solutions that match the best motor/generator
for a given location, wind potential and turbine used. We
have
the ability to model many possible scenarios including some, like the
example below, that allow you to try multiple motor/generators and wind
studies for a single turbine. In this study, the fields in red are
entered and the software then generates six wind models for use with
the eight entered motor/generators. Summary information about the
energy generated, turbine limits and each motor/generator are then
shown. Additionally, information about the turbine, each wind model,
each motor/generator and the energy generated by each scenario is
created.
Click on the above picture to see the full-size Data Entry / Summary page.
Click on the above picture to see a sample Turbine Information page.
Click on the above picture to see a sample Turbine Power Generation page.
Click on the above picture to see a sample Weibull Wind Distribution page.
Click on the above picture to see a sample Motor / Generator Information page.
Click on the above picture to see a sample Motor / Generator Power Curve page.
Click on the above picture to see a sample Energy Information page.
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